CARTON WITH TOP GUSSET

• US 20100127061A1
• Filed: 11/20/2009
• Published: 05/27/2010
• Est. Priority Date: 11/21/2008
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Strand, Scott T., Burke, Bradley J.
• Granted Patent: US 8,770,469 B2
• Time in Patent Office: Days
• US Class Current: 229/165
• CPC Class Codes: B65D 25/54 Inspection openings or windows
• CPC Class Codes: B65D 5/18 by folding a single blank to U-shape to form the base of the container and opposite sides of the body portion, the remaining sides being formed primarily by extensions of one or more of these opposite sides, e.g. flaps hinged thereto B65D5/36 takes precedence
• CPC Class Codes: B65D 5/302 combined with a slot provided in an adjacent side wall
• CPC Class Codes: B65D 5/545 for opening containers formed by erecting a "cross-like" blank
• CPC Class Codes: B65D 5/548 for opening containers formed by erecting a blank to U-shape
• CPC Class Codes: B65D 5/6635 the lid-halves being held in closed position by flaps or tabs provided at their edge opposite to their hinge B65D5/6644, B65D5/6647 take precedence
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24273 including aperture

Abstract

A carton for holding a plurality of articles. The carton comprises a gable top comprising two top panels at a top of the carton. The gable top comprises at least one gusset foldably connected to a side flap and one of the top panels. The first and second top flaps angle inwardly from a respective front panel and back panel of the carton.

Claims

1. A carton for containing a plurality of articles, the carton comprises:

a plurality of panels that extend at least partially around the interior of the carton, the panels comprise

a front panel,

a first top panel foldably connected to the front panel,

a bottom panel foldably connected to the front panel,

a back panel foldably connected to the bottom panel, and

a second top panel foldably connected to the back panel, wherein one of the front and back panels at least partially forms a lid and the other of the front and back panels at least partially forms a tray;

at least one side flap foldably connected to at least one of the front and back panels; and

at least one gusset foldably connected to the at least one side flap and one of the first and the second top panels, wherein the first and second top panels angle inwardly from a respective front panel and back panel and are at least partially in face-to-face contact to form a top of the carton.

2. The carton of claim 1 wherein the at least one side flap comprises a first back side flap foldably connected to the back panel and a second back side flap foldably connected to the back panel, the bottom panel, the back panel, the first back side flap, the second back side flap, the at least one gusset, and the second top panel at least partially form the tray.

3. The carton of claim 2 further comprising a first bottom flap foldably connected to the bottom panel and a second bottom flap foldably connected to the bottom panel.

4. The carton of claim 3 wherein each of the first and second bottom flaps comprise a locking portion and the first and second back side flaps each comprise a respective cut that receives the locking portion of the respective first and second bottom flap.

5. The carton of claim 4 wherein the first and second bottom flaps are each at least partially in face-to-face contact with an external surface of the respective first and second back side flaps.

6. The carton of claim 2 further comprising a first front side flap foldably connected to the front panel, and a second front side flap foldably connected to the front panel, the first front side flap, the second front side flap, the front panel, and the first top panel at least partially form the lid.

7. The carton of claim 6 wherein the at least one gusset comprises a first gusset and a second gusset, each of the first gusset and the second gusset comprises a first gusset panel foldably connected to a respective one of the first back side flap and the second back side flap, and a second gusset panel foldably connected to the first gusset panel and one of the first top panel and the second top panel.

8. The carton of claim 7 wherein each first gusset panel is connected to a respective second gusset panel at an oblique fold line.

9. The carton of claim 8 wherein the first gusset is connected to the second top panel at a first longitudinal fold line and the second gusset is connected to the second top panel at a second longitudinal fold line.

10. The carton of claim 7 wherein the first top panel comprises a first base portion foldably connected to the front panel and a first top flap at a respective marginal portion of the first top panel, and the second top panel comprises a second base portion foldably connected to the back panel and a second top flap at a respective marginal portion of the second top panel.

11. The carton of claim 10 wherein the first and second base portions slope inwardly from a respective front and back panel, and the first and second top flaps are at least partially in face-to-face contact and are in a generally parallel planar relationship with the front and back panels.

12. The carton of claim 11 wherein the first top flap is adhered to the second top flap.

13. The carton of claim 10 wherein the second gusset panels of each of the first and second gussets are in face-to-face contact with the second base portion.

14. The carton of claim 11 wherein each of the second gusset panels is adhered to the second base portion.

15. The carton of claim 7 wherein each first gusset panel is foldably connected to a respective one of the first and second back side flaps at a first oblique fold line and each second gusset panel is foldably connected to a respective one of the first and second back side flaps at a second oblique fold line.

16. The carton of claim 15, wherein the first and second oblique fold lines are arranged to form an inverted V shape with the second oblique fold line extending from a transverse fold line connecting the second base portion to the back panel and the first and second gusset panels meet at the apex of the inverted V shape.

17. The carton of claim 16 wherein the at least one side flap further comprises a first front side flap foldably connected to the front panel and a second front side flap foldably connected to the front panel, and each of the first and second front side flaps comprises two oblique edges that form a pointed end proximate to the first top panel.

18. The carton of claim 15 wherein the at least one gusset further comprises a third gusset and a fourth gusset, each of the third gusset and the fourth gusset comprises a gusset panel connected to the first top panel.

19. The carton of claim 18 wherein the at least one side flap further comprises a first front side flap foldably connected to the front panel and a second front side flap foldably connected to the front panel, and the gusset panel of each of the third gusset and the fourth gusset is foldably connected to a respective one of the first and second front side flaps at a respective oblique fold line.

20. The carton of claim 10 wherein each of the first gusset and the second gusset comprises a third gusset panel foldably connected to the first gusset panel, wherein each of the third gusset panels is adhered to the first base portion.

21. The carton of claim 20 wherein for each of the first and second gussets, the first gusset panel is foldably connected to the second and third gusset panels at a respective first and second oblique fold line.

22. The carton of claim 20 wherein the first back side flap is connected to the back panel at a first longitudinal fold line, the second back side flap is connected to the back panel at a second longitudinal fold line, and each first gusset panel is foldably connected to a respective one of the first and second back side flaps at a respective lateral fold line.

23. The carton of claim 1, further comprising a dispenser that comprises at least one tear line extending at least partially across at least one of the front and back panels.

24. The carton of claim 23, the at least one tear line comprises a first tear line extending in the back panel and a second tear line extending in the front panel, at least one of the first and second tear lines extending across at least a portion of the at least one side flap.

25. The carton of claim 24, the second tear line extending generally laterally across at least a portion of the front panel.

26. The carton of claim 24, the first tear line comprises a first oblique portion and a second oblique portion, the first and second oblique portions converging on a finger flap in the back panel.

27. The carton of claim 1, the front panel defining an opening, wherein a generally transparent film is applied to the front panel to at least partially cover the opening.

62. The method of claim 1, wherein the front panel comprises an opening, the method further comprises positioning a generally transparent film relative to the front panel to at least partially cover the opening.

28. A blank for forming a carton for holding a plurality of articles, the blank comprises:

a plurality of panels that comprise

a front panel,

a first top panel foldably connected to the front panel,

a bottom panel foldably connected to the front panel,

a back panel foldably connected to the bottom panel, and

a second top panel foldably connected to the back panel, wherein one of the front and back panels is for forming a lid in the carton formed from the blank and the other of the front and back panels is for forming a tray in the carton formed from the blank;

at least one side flap foldably connected to at least one of the front and back panels; and

at least one gusset foldably connected to the at least one side flap and one of the first and the second top panels, wherein the first and second top panels are for being positioned to angle inwardly from a respective front panel and back panel and are for being positioned to be at least partially in face-to-face contact to form a top of the carton formed from the blank.

29. The blank of claim 28 wherein the at least one side flap comprises a first back side flap foldably connected to the back panel and a second back side flap foldably connected to the back panel.

30. The blank of claim 29 further comprising a first bottom flap foldably connected to the bottom panel and a second bottom flap foldably connected to the bottom panel.

31. The blank of claim 30 wherein each of the first and second bottom flaps comprise a locking portion and the first and second back side flaps each comprise a respective cut that receives the locking portion of the respective first and second bottom flap.

32. The blank of claim 29 further comprising a first front side flap foldably connected to the front panel, and a second front side flap foldably connected to the front panel.

33. The blank of claim 32 wherein the at least one gusset comprises a first gusset and a second gusset, each of the first gusset and the second gusset comprises a first gusset panel foldably connected to a respective one of the first back side flap and the second back side flap, and a second gusset panel foldably connected to the first gusset panel and one of the first top panel and the second top panel.

34. The blank of claim 33 wherein each first gusset panel is connected to a respective second gusset panel at an oblique fold line.

35. The blank of claim 34 wherein the first gusset is connected to the second top panel at a first longitudinal fold line and the second gusset is connected to the second top panel at a second longitudinal fold line.

36. The blank of claim 33 wherein the first top panel comprises a first base portion foldably connected to the front panel and a first top flap at a respective marginal portion of the first top panel, and the second top panel comprises a second base portion foldably connected to the back panel and a second top flap at a respective marginal portion of the second top panel.

37. The blank of claim 32 wherein each first gusset panel is foldably connected to a respective one of the first and second back side flaps at a first oblique fold line and each second gusset panel is foldably connected to a respective one of the first and second back side flaps at a second oblique fold line.

38. The blank of claim 37 wherein the first and second oblique fold lines are arranged to form an inverted V shape with the second oblique fold line extending from a transverse fold line connecting the second base portion to the back panel and the first and second gusset panels meet at the apex of the inverted V shape.

39. The blank of claim 38 wherein the at least one side flap further comprises a first front side flap foldably connected to the front panel and a second front side flap foldably connected to the front panel, and each of the first and second front side flaps comprises two oblique edges that form a pointed end proximate to the first top panel.

40. The blank of claim 37 wherein the at least one gusset further comprises a third gusset and a fourth gusset, each of the third gusset and the fourth gusset comprises a gusset panel connected to the first top panel.

41. The blank of claim 40 wherein the at least one side flap further comprises a first front side flap foldably connected to the front panel and a second front side flap foldably connected to the front panel, and the gusset panel of each of the third gusset and the fourth gusset is foldably connected to a respective one of the first and second front side flaps at a respective oblique fold line.

42. The blank of claim 33 wherein each of the first gusset and the second gusset comprises a third gusset panel foldably connected to the first gusset panel, wherein each of the third gusset panels is adhered to the first base portion.

43. The blank of claim 42 wherein for each of the first and second gussets, the first gusset panel is foldably connected to the second and third gusset panels at a respective first and second oblique fold line.

44. The blank of claim 42 wherein the first back side flap is connected to the back panel at a first longitudinal fold line, the second back side flap is connected to the back panel at a second longitudinal fold line, and each first gusset panel is foldably connected to a respective one of the first and second back side flaps at a respective lateral fold line.

45. The blank of claim 28, further comprising a dispenser panel at least partially defined by at least one tear line extending at least partially across at least one of the front and back panels.

46. The blank of claim 45 wherein the at least one tear line comprises a first tear line extending in the back panel and a second tear line extending in the front panel, at least one of the first and second tear lines extending across at least a portion of the at least one side flap.

47. The blank of claim 28 wherein the front panel comprises an opening, and the blank comprises a generally transparent film is applied to the front panel to at least partially cover the opening.

58. The method of claim 35 wherein the at least one gusset further comprises a third gusset and a fourth gusset, each of the third gusset and the fourth gusset comprises a gusset panel connected to the first top panel.

59. The method of claim 58 wherein the at least one front side flap comprises a first front side flap foldably connected to the front panel and a second front side flap foldably connected to the front panel, and the gusset panel of each of the third gusset and the fourth gusset is foldably connected to a respective one of the first and second front side flaps at a respective oblique fold line.

48. A method of forming a carton for containing a plurality of articles, the method comprises:

obtaining a carton blank, the carton blank comprises

a plurality of panels comprising a front panel, a first top panel foldably connected to the front panel, a bottom panel foldably connected to the front panel, a back panel foldably connected to the bottom panel, and a second top panel foldably connected to the back panel,

at least one front side flap foldably connected to the front panel,

at least one back side flap foldably connected to the back panel, and

at least one gusset foldably connected to one of the first and the second top panels;

forming a tray by folding the bottom panel, the second top panel and the at least one back side flap relative to the back panel;

forming a lid by folding the first top panel and the at least one front side flap relative to the front panel;

closing the carton by folding the lid and positioning the first and second top panels to angle inwardly from a respective front panel and back panel so that the first and second top panels are at least partially in face-to-face contact to the top of the carton.

49. The method of claim 48 wherein the at least one back side flap comprises a first back side flap foldably connected to the back panel and a second back side flap foldably connected to the back panel, and forming the tray comprise positioning the bottom panel, the back panel, the first back side flap, the second back side flap, the at least one gusset, and the second top panel.

50. The method of claim 49 wherein the blank further comprises a first bottom flap foldably connected to the bottom panel and a second bottom flap foldably connected to the bottom panel, the forming the tray comprises positioning the first bottom flap into face-to-face contact with the first back side flap and positioning the second bottom flap into face-to-face contact with the second back side flap.

51. The method of claim 50 wherein each of the first and second bottom flaps comprise a locking portion and the first and second back side flaps each comprise a respective cut, and forming the tray comprises placing each respective locking portion into a respective cut to place the first and second bottom flaps into interlocking engagement with a respective first and second back side flap.

52. The method of claim 49 wherein the at least one front side flap comprises a first front side flap foldably connected to the front panel, and a second front side flap foldably connected to the front panel, and forming the lid comprises positioning the first front side flap, the second front side flap, the front panel, and the first top panel.

53. The method of claim 52 wherein the at least one gusset comprises a first gusset and a second gusset, each of the first gusset and the second gusset comprises a first gusset panel foldably connected to a respective one of the first back side flap and the second back side flap, and a second gusset panel foldably connected to the first gusset panel and the one of the first top panel and the second top panel.

54. The method of claim 53 wherein the first top panel comprises a first base portion foldably connected to the front panel and a first top flap at a respective marginal portion of the first top panel, and the second top panel comprises a second base portion foldably connected to the back panel and a second top flap at a respective marginal portion of the second top panel, wherein closing the carton comprises positioning the first and second base portions slope to inwardly from a respective front and back panel, and positioning the first and second top flaps to be in face-to-face contact and in a generally parallel planar relationship with the front and back panels.

55. The method of claim 54 wherein closing the carton comprises adhering the first top flap to the second top flap.

56. The method carton of claim 54 wherein closing the carton comprises positioning the second gusset panels of each of the first and second gussets in face-to-face contact with the second base portion and positioning the first gusset panels of each of the first and second gussets between the first base portion and the second base portion to close the sides of the carton.

57. The method of claim 56 wherein closing the carton comprises adhering each of the second gusset panels to the second base portion.

60. The method of claim 54 wherein each of the first gusset and the second gusset comprises a third gusset panel foldably connected to the first gusset panel, wherein closing the carton comprises adhering each of the third gusset panels to the first base portion.

61. The method of claim 48 wherein the blank further comprises a dispenser that comprises at least one tear line extending at least partially across at least one of the front and back panels, and the method further comprises opening the carton by at least partially separating the dispenser panel from the carton at the tear line.